Complete replacement of all rocker arms on the 2015 Kia Forte 1.8L I4 engine, including removal of valve cover, camshafts, and hydraulic lash adjusters.

Warnings

Tools required

Parts

• Rocker arm (exhaust) × 8 — Use OEM specification
• Rocker arm (intake) × 8 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Valve cover bolt grommets × 12 — Use OEM specification
• Camshaft bearing cap bolts (if reuse not recommended) × 10 — Use OEM specification
• Engine oil × 1 — Kia Genuine 5W-20

Fluids

• Kia Genuine 5W-20 — 4.5 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery cable and secure away from terminal
3. Remove engine cover by pulling upward on pull tabs
4. Remove air intake duct and air filter housing assembly
5. Disconnect all electrical connectors from valve cover (PCV, ignition coils)
6. Label and photograph all vacuum hoses and electrical connections for reassembly
7. Place drain pan under engine and verify oil drain plug is tight
8. Take photographs of timing marks and camshaft positions before disassembly

Procedure

1. 1

   Remove ignition coils and spark plugs
   Remove the four ignition coil connectors. Remove coil mounting bolts and extract ignition coils from spark plug wells. Remove all four spark plugs to allow free engine rotation and reduce compression resistance during reassembly.
2. 2

   Remove valve cover assembly
   Disconnect PCV hose and breather hose from valve cover. Remove valve cover bolts in reverse of tightening sequence (start from outside, work inward). Carefully lift valve cover straight up to avoid damaging gasket surface. If stuck, gently tap with rubber mallet - do not pry.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
3. 3

   Verify timing marks and lock engine at TDC
   Rotate crankshaft clockwise (viewed from front) using 22mm socket on crankshaft pulley bolt until cylinder #1 is at TDC on compression stroke. Verify timing marks on camshaft sprockets align with cylinder head surface or timing marks. Take detailed photographs. Do not rotate engine again until reassembly is complete.
   ⚠Failure to properly mark timing position will result in engine damage upon startup.
4. 4

   Remove timing chain components access
   Remove timing chain cover upper section if equipped (models may vary). This provides access to camshaft sprocket bolts. You may need to remove engine mount bracket to access timing cover bolts. Support engine weight with jack and wooden block under oil pan if removing mount.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)

   Mounting Bolts45 Nm (33 lb-ft)
5. 5

   Secure timing chain and remove camshaft sprockets
   Using zip ties or wire, secure timing chain to prevent it from dropping into timing cover. Mark relationship between camshaft sprockets and timing chain with paint pen. Remove camshaft sprocket bolts while holding camshaft with wrench on hex section (between lobes 2 and 3). Carefully slide sprockets off camshafts while keeping chain supported and in position.
   ⚠️Timing chain is under tension. Secure chain before removing sprockets to prevent chain from falling into engine.
6. 6

   Remove camshaft bearing caps
   Loosen camshaft bearing cap bolts gradually in multiple passes (3-4 passes), working from outside bolts toward center to release valve spring tension evenly. Bearing caps are numbered 1-5 and marked with I (intake) or E (exhaust) and directional arrows. Keep caps organized in exact order with their bolts. Remove bearing caps and set aside in order.
   ⚠Loosening bearing caps unevenly or too quickly can warp camshafts or damage bearing surfaces.
   Torque spec

   Mounting Bolts45 Nm (33 lb-ft)
7. 7

   Remove camshafts
   Carefully lift intake camshaft straight up and out of cylinder head. Repeat for exhaust camshaft. Place camshafts on clean, padded surface where they will not roll. Do not allow camshafts to contact hard surfaces that could damage bearing journals or lobes.
8. 8

   Remove and organize rocker arms and lash adjusters
   Remove all 16 rocker arms from their positions on the hydraulic lash adjusters. Use magnetic parts tray or numbered containers to keep each rocker arm in order (I1, I2, I3, I4 for intake, E1-E4 for exhaust, both sides). Remove all 16 hydraulic lash adjusters and keep them organized in the same manner. Mark intake vs exhaust. Even if replacing rocker arms, lash adjusters should be returned to original positions unless also being replaced.
   ℹ️Hydraulic lash adjusters must be stored upright in clean engine oil to prevent air from entering. Do not lay them on their sides.
9. 9

   Inspect and clean all components
   Thoroughly clean cylinder head valve train area with clean rags and brake cleaner. Inspect camshaft lobes and bearing journals for scoring, wear, or discoloration. Inspect rocker arm contact surfaces (cam follower and valve stem contact points) for pitting or uneven wear. Verify new rocker arms match original specifications. Check that all oil passages in cylinder head are clear.
10. 10

    Install hydraulic lash adjusters
    Lubricate each hydraulic lash adjuster with fresh engine oil. Install each lash adjuster into its original bore in the cylinder head. Ensure adjusters are fully seated and can rotate freely in their bores. Lash adjusters should be upright and filled with oil - do not compress plunger excessively during installation.
11. 11

    Install new rocker arms
    Generously lubricate each new rocker arm on both the cam follower surface and valve stem contact point with clean engine oil. Install rocker arms onto their respective lash adjusters, maintaining intake and exhaust positions. Ensure rocker arms move freely on lash adjusters and align properly with valve stems.
12. 12

    Reinstall camshafts
    Coat all camshaft bearing journals and cam lobes liberally with fresh engine oil or assembly lube. Carefully lower intake camshaft into position in cylinder head, ensuring it seats properly in bearing saddles. Verify cam lobes face correct direction (compare to photographs). Repeat for exhaust camshaft. Ensure camshafts are positioned exactly as they were during removal for proper timing.
    ⚠Camshafts must be installed in correct timing position or engine will not run and may suffer valve-to-piston contact damage.
13. 13

    Install camshaft bearing caps and torque
    Install bearing caps in their exact original positions, observing numbers, intake/exhaust markings, and directional arrows (arrows point toward timing chain). Hand-tighten all bearing cap bolts. Torque bearing cap bolts gradually in multiple passes (3-4 passes) from center outward to the specified torque, allowing valve springs to compress evenly. Final torque is 19 Nm (14 lb-ft) per gasket bolts specification.
    Torque spec

    Gasket Bolts19 Nm (14 lb-ft)
14. 14

    Reinstall camshaft sprockets and verify timing
    Verify camshafts are still at TDC position. Align timing marks on camshaft sprockets with marks made during removal. Install sprockets onto camshafts while aligning timing chain with marks on sprockets. Remove chain support ties/wire. Install and torque camshaft sprocket bolts per manufacturer specification (typically 90-100 Nm but verify in service manual). Rotate engine by hand two complete revolutions and verify all timing marks realign perfectly.
    ⚠️Do not start engine if timing marks do not align after two rotations. Recheck all timing procedures.
15. 15

    Reinstall timing cover and valve cover
    Clean all gasket surfaces thoroughly with razor blade scraper and brake cleaner. Install new valve cover gasket and grommets. Apply small dab of RTV silicone to corners where timing cover meets cylinder head (if applicable per service manual). Install valve cover and torque bolts in sequence from center outward to 10 Nm (7 lb-ft). Reinstall timing chain cover components if removed.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

Reassembly

1. Reinstall spark plugs and torque to specification (not provided - consult service manual)
2. Reinstall ignition coils and reconnect electrical connectors
3. Reinstall air intake system and engine cover
4. Reconnect negative battery cable
5. Refill engine oil to proper level with Kia Genuine 5W-20 (4.5 quarts total capacity)
6. Do not start engine immediately - allow lash adjusters to settle for 30 minutes if possible

Verification

• Start engine and listen for abnormal valve train noise - slight ticking for first 10-30 seconds is normal as lash adjusters pump up
• Verify no oil leaks from valve cover gasket after engine reaches operating temperature
• Check for proper engine idle and smooth acceleration with no misfires
• Monitor oil pressure gauge to ensure normal pressure
• After 500 miles, inspect valve cover area for any oil seepage and retorque valve cover bolts if necessary
• Listen for any abnormal ticking, tapping, or grinding noises from valve train during cold and hot operation

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